Floors
Tools Required
Rivet Gun
Drill
3/16th drill bit for rivets
4 quick-style clamps
Cheap brush or rag for wiping metal shavings
Optional: Rivet Gun Conversion for Reversible Drills
Parts Needed
Frame
Aluminum Floors
Rivets
Hopefully this will be the only time your Exocet will be in this position. Take your chassis, and flip it upside down on a level surface. Use towels or some other protection for the powdercoated frame. Powdercoat is tough, but any scratches from this position will be very visible.
Mock up the aluminum floors on the chassis; they are symmetric and only go on one way. They are not supposed to line up with the outer edge of the tube, they actually sit inside of the tube’s edge radius. Now, notice the little pre-lasered holes that happen to line up with the floor tubes? You’re going to use those as guides for your drill. Take your quick-clamps and use them to secure one of the floors into position. Make sure the floor is flat along the tubes before starting.
Now that you have one of the floors clamped to the chassis, you can use a 3/16″ drill bit to continue all the holes. The bit should self-align in the laser-cut aluminum holes, but if you’re having trouble, grab your center punch and use that. Make sure to remember the holes on the cross-tubes in the middle.
Once you have all the holes drilled, carefully take off the clamps and lift off the floor. Brush off all the steel and aluminum swarf (shavings) from the frame and aluminum panel. Repeat the same process for the other side.
Optional step: A thin bead of sealant between the frame and floors will help prevent rattles in the long run. RTV or silicone is the best choice. Be sure to wipe off any excess immediately.
Now, reposition the floors on the frame. Drop in all your rivets before actually riveting anything together, they’ll make sure everything stays perfectly aligned. Once you have all the rivets in, start riveting, working your way in one direction (front of the car to back of the car is an example). A pneumatic rivet gun can help, but it’s not a necessity.
Once all the rivets are done, your floors are complete. If you added sealant, check for excess again. Notice the cutouts in the aluminum floors at the four corners? Those are your reinforced jacking points. Cool, huh?
TL;DR: Clamp on the aluminum floors, drill out the holes, use some sealant, and rivet them to the chassis.
